APRILIA RSV4 Factory a-PRC 2009 Guide

SERVICE STATION MANUAL
898952
RSV4 Factory a-PRC

SERVICE STATION
MANUAL
RSV4 Factory a-PRC
THE VALUE OF SERVICE
As a result of continuous updates and specific technical training programmes for Aprilia products, only
Aprilia Official Network mechanicsknowthisvehiclefullyandhavethespecifictoolsnecessarytocarry
out maintenance and repair operations correctly.
Thereliabilityofthevehiclealsodependsonitsmechanicalconditions.Checkingthevehiclebeforeriding
it, its regular maintenance and the use of original Aprilia spare parts only are essential factors!
For information on the nearest Official Dealer and/or Service Centre consult our website:
www.aprilia.com
Only by requesting aprilia original spare parts can you be sure of purchasing products that were
developed and tested during the actual vehicle design stage. All aprilia original spare parts undergo
quality control procedures to guarantee reliability and durability.
Thedescriptionsandimagesinthispublicationaregivenforillustrativepurposesonlyandarenotbinding.
While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio &
C.S.p.A. reserves the right, at anytime and without being required toupdate this publication beforehand,
to make any changes to components, parts or accessories, which it considers necessary to improve the
product or which are required for manufacturing or construction reasons.
Notallversions/modelsshowninthispublicationareavailableinallcountries.Theavailabilityofindividual
versions/models should be confirmed with the official aprilia sales network.
The Aprilia trademark is the property of Piaggio & C. S.p.A.
© Copyright 2011 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com

SERVICE STATION MANUAL
RSV4 Factory a-PRC
This manual provides the main information to carry out regular maintenance operations on your vehicle.
This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to
continually improve its products and the relative documentation. The main technical modifications and
changes in repair procedures are communicated to all aprilia Sales Outlets and its International
Subsidiaries.These changes will be introduced inthe subsequent editions of the manual.Incase of need
or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which
will be prepared to provide any information on the subject and any further communications on updates
and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,A POISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VA-
POURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Coolant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO POUR COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN CARRYING
OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN
THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRAC-
TIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCES-
SIBLE TO ANIMALS AS THEY MAY DRINK IT.
RSV4 Factory a-PRC Characteristics
CHAR - 7

KEEP OUT OF THE REACH OF CHILDREN
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-
HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS
WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID
IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH
THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK
MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTSOFBATTERY ACIDMAYCAUSE BLINDNESS.IF THEFLUIDGETS INCONTACTWITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING COMPONENTS
Characteristics RSV4 Factory a-PRC
CHAR - 8

•Beforedismantling components, remove dirt, mud, dust and foreign bodies fromthe vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donot loosen and/or tighten screws and nuts using pliers or any other tools than thespecific
wrench.
•Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
•Each component needs to be clearly marked to enable identification during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
•Keep mated parts together since they have "adjusted" to each other due to normal wear.
•Some components must be used together or replaced completely.
•Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
•Only use ORIGINAL Aprilia SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•Whentighteningnuts and screws, starteitherfromthecomponentswith the largest diameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
•Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRICAL CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
•Grip the two connectors and disconnect them by pulling them in opposite directions.
RSV4 Factory a-PRC Characteristics
CHAR - 9

•If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•Ensure that the cables are correctly fastened to the internal connector terminals.
•Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBERTHATTHE TIGHTENINGTORQUESFOR ALLFASTENING ELEMENTSONWHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Runningthe engine in correctly isessential for ensuring enginelongevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "unloaded" conditions, allowing the engine components to cool.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow the guidelines detailed below:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. That is to permit the adequate adjustment of the pad friction material to the brake
discs.
•It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm
up 2000 km (1243 mi).
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE
CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-
TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE
VEHICLE.
Characteristics RSV4 Factory a-PRC
CHAR - 10

Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.
This number consists of numbers and letters, as in
the example shown below.
ZD4RKB000YSXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
RK: model;
B00: version variation;
0: free digit
Yyear of manufacture
S: production plant (S= Scorzè);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right hand
side of the headstock.
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 2040 mm (80.31 in)
Max. width (at handlebar) 735 mm (28.94 in)
Max. height (to windshield) 1120 mm (44.09 in)
Saddle height 847 mm (33.35 in)
Wheelbase 1420 mm (55.90 in)
Minimum ground clearance 130 mm (5.12 in)
Dry weight 189 kg (417 lb)
Kerb weight 200 kg (441 lb)
Full loaded weight (rider only) 275 kg (441 lb)
RSV4 Factory a-PRC Characteristics
CHAR - 11

Engine
ENGINE
Specification Desc./Quantity
Model V4
Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double
overhead camshafts.
Engine capacity 999 cm³ (60.96 cu.in)
Bore / stroke 78 mm / 52.26 mm (3.07 in / 2.06 in)
Compression ratio 13 : 1
Engine idle speed 1400 ± 100 rpm
Engine revs at maximum speed 14000 ± 100 rpm
Clutch Multiplate wet clutch with mechanical control lever on left side
of the handlebar Anti-juddering and slipper clutch systems
Electric Electric starter
Timing system Morse chain on intake camshaft, cam to cam gear, bucket tap-
pets and valve clearance adjustments with calibrated pads
Acceptable values with control clearance between cam and
valve Intake:0.10-0.15mm(0.0039 - 0.0059 in)exhaust: 0.20 - 0.25 mm (0.0079 - 0.0098 in)
Lubrication Wet sump with oil radiator
Oil pump Dual trochoidal pump (lubrication + cooling)
Oil filter With external cartridge filter
Cooling Fluid
Cooling system 3-way thermostatic valve, cooling radiator with electric fan and
expansion tank
Coolant pump Centrifugal bearingless aspirating pump with integrated ce-
ramic gasket
Air filter In cotton
Alternatively:
Air filter Paper
Transmission
GEAR RATIOS
Specification Desc./Quantity
Primary drive ratio 44 / 73 (with gears)
1st gear ratio 16 / 38 (secondary)
2nd gear ratio 18 / 35 (secondary)
3rd gear ratio 17 / 28 (secondary)
4th gear ratio 22 /32 (secondary)
5th gear ratio 26 /34 (secondary)
6th gear ratio 27 /33 (secondary)
Final drive gear ratio 16 / 42
TRACTION CONTROL
Specification Desc./Quantity
a-PRC system (Aprilia Performance Ride Control), which includes traction
control,wheeliecontrol,launchcontrolandclutchlessgearshift
functions.
Capacities
CAPACITY
Specification Desc./Quantity
Fuel capacity (reserve included) 17 l (3.74 UK gal)
Fuel tank reserve 3.6 l (0.79 UK gal)
Engine oil oil and filter change 4 l (0.88 UK gal)
Coolant 2.7 l (0.59 UK gal)
Characteristics RSV4 Factory a-PRC
CHAR - 12

Specification Desc./Quantity
Seats 1 + 1
Two seat configuration: if vehicle is fitted with footrests and
saddle for passenger
Maximum weight capacity 201 kg (443 lb)
Fork oil 530 cc (0.12 Uk gal) (for each stanchion)
Drive chain
DRIVE CHAIN
Specification Desc./Quantity
Type 525
With sealed master link
Model Regina 110 links
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plugs NGK-R CR9EKB
Alternatively:
NGK-R CR9EB
NGK-R CR10E (for competition use)
Electrode gap 0.7 - 0.8 mm (0.027 - 0.031 in)
Battery YUASA YT12A-BS, 12 V 9.5 Ah or YUASA YTZ10S, 12 V 8.6
Ah
Coils Stick coil
Recharging system Flywheel with rare earth magnets
Generator 450 W
Main fuses 30 A
Auxiliary fuses 5A - 7.5A - 15A
BULBS
Specification Desc./Quantity
Low/high beam headlight 12V - 55W H11
Front daylight running light 12V - 5W
Turn indicators 12V - 10W (White light)
Rear daylight running light / stop light LED
Licence plate light 12V - 5W
WARNING LIGHTS
Specification Desc./Quantity
High beam light LED
Right turn indicator LED
Left turn indicator LED
General warning LED
Gear in neutral LED
Side stand down LED
Fuel reserve LED
ABS NOT ENABLED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type Adjustable aluminium, dual beam chassis with pressed and
cast sheet elements.
RSV4 Factory a-PRC Characteristics
CHAR - 13

Specification Desc./Quantity
Steering rake 26.5° (measurements with reference to bare frame). For the
Factory versions the adjustments allow for variations of "+" or
"-" 1°
Trail 110 mm (4.33 in)
(with adjustable inserts, headstock as a standard feature)
SUSPENSION
Specification Desc./Quantity
Front fork Öhlins upside down units with adjustable hydraulic damping
and 43 mm (1.69 in) diam. stanchions with Tin surface coating)
Front wheel travel 120 mm (4.72 in)
Rear shock absorber Lateral, with progressive linkage and APS system. ÖHLINS
piggy-back shock absorber with adjustable spring preloading,
wheelbase and hydraulic compression and rebound damping.
Rear wheel travel 130 mm (5.12 in)
SIZES A AND B
Specification Desc./Quantity
Size "A" 639.5 mm (25.18 in) (measurements refer to the bare chassis)
Size "B" 329.5 mm (12.97 in) (measurements refer to the bare chassis)
Brakes
BRAKES
Specification Desc./Quantity
Front Dual 320 mm (12.59 inches) diam. floating disc, single block
calipers with radial fixing and four pistons 34 mm diam. (1.34
inches) and 2 pads - radial pump and brake pipe in metal braid.
Rear disc type -220 mm diam. (8.66 inches), 2-piston callipers - 32
mm diam. (1.25 inches) - pump with built-in tank and metal
braid pipe.
Wheels and tyres
WHEEL RIMS
Specification Desc./Quantity
Front wheel rim 3.50 x 17" Forged
Rear wheel rim 6.00 x 17" Forged
TYRES
Specification Desc./Quantity
Tyre model Pirelli DIABLO Super Corsa SP
Metzeler RACETEC K3
Michelin Power One
Characteristics RSV4 Factory a-PRC
CHAR - 14

Specification Desc./Quantity
Dunlop SPORTMAX GP Racer (Mixture "M" Front)
Dunlop SPORTMAX GP Racer (Mixture "E" Rear)
Front tyre 120/70 ZR17 (58W)
Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)
2 passengers: 2.5 bar (250 kPa) (36.26 PSI)
Rear tyre 200/55 ZR17 (78W) (*)
190/55 ZR17 (75W)
190/50 ZR17 (73W)
(*) With these dimensions use only Pirelli Diablo Super-
corsa SP tyres.
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
FUEL SYSTEM
Specification Desc./Quantity
Throttle body diameter 48 mm (1.89 in)
Type Electronic injection with 2 injectors per cylinder, 4 motorised
throttle bodies (Ride by Wire). Variable length intake ducts. 2
dynamic air intakes. Multiple selectable maps.
Tightening Torques
Chassis
Front side
RSV4 Factory a-PRC Characteristics
CHAR - 15

OIL RADIATOR
pos. Description Type Quantity Torque Notes
1 Screws fastening oil radiator to
mounting bracket M6 1 7 Nm (5.16 lbf ft) -
FRONT FORK
pos. Description Type Quantity Torque Notes
1 Fastener screws for calliper mount-
ing bracket (Öhlins) M6 2 + 2 12 Nm (8.85 lb ft) -
2 Odometer sensor fixing screw M6 1 10 Nm (7.38 lb ft) -
- Speed sensor bracket screws - 1 - -
Characteristics RSV4 Factory a-PRC
CHAR - 16

STEERING
pos. Description Type Quantity Torque Notes
1Screwsfastening upperyoke tostan-
chions M8 2 25 Nm (18.44 lb ft) -
2Screws fastening lower yoke to stan-
chions M8 4 25 Nm (18.44 lb ft) -
3 Headstock lock ring M35x1 1 60 Nm (44.25 lbf ft) -
4 Headstock counter-lock ring M35x1 1 Manual +35° or -10° Bend the tabs into
the notches in the
lock ring
5 Upper yoke fixing cap - 1 100 Nm (73.76 lb ft) -
6 Screw fastening shock absorber to
frame M6 1 10 Nm (7.37 lb ft) -
7 Screw fastening shock absorber to
lower yoke M6 1 10 Nm (7.37 lb ft) -
RSV4 Factory a-PRC Characteristics
CHAR - 17

FRONT WHEEL
pos. Description Type Quantity Torque Notes
1 Front wheel spindle nut M25x1.5 1 80 Nm (59 lb ft) -
2 Front brake disc fixing screws M8 6 + 6 30 Nm (22.13 lb ft) Loct. 243
FRONT BRAKE CALLIPER
pos. Description Type Quantity Torque Notes
1 Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) -
Characteristics RSV4 Factory a-PRC
CHAR - 18

FRONT BRAKE PUMP
pos. Description Type Quantity Torque Notes
1Screw fastening front brake fluid res-
ervoir to bracket M6 1 7 Nm (5.16 lbf ft) -
2Screw fastening brake fluid reservoir
mounting bracket to handlebar M6 1 7 Nm (5.16 lbf ft) -
3Screw fastening brake pipe grommet
to the lower yoke M5 1 8 Nm (5.9 lbf ft) -
4 Front brake pump U bolt clamp M6 2 10 Nm (7.37 lbf ft) -
5 Front brake lever pin fixing screw M6 1 10 Nm (7.37 lbf ft) -
RSV4 Factory a-PRC Characteristics
CHAR - 19

HANDLEBAR AND CONTROLS
pos. Description Type Quantity Torque Notes
1 Screw fastening the semi-handlebar
collar to the fork sleeves M8 1 + 1 25 Nm (18.44 lbf ft) -
2 Semi-handlebar safety screw M6 1+1 10 Nm (7.37 lbf ft) -
3Anti-vibrationcounterweightfastener M18x1.5 1+1 20 Nm (14.75 lbf ft) -
4 Right light switch M4 2 1.5 Nm (1.11 lbf ft) -
5 Left light switch M5 2 1.5 Nm (1.11 lbf ft) -
6 Throttle control fixing screws M5 2 2 Nm (1.47 lbf ft) -
7 Traction control control unit fixing
screw M4 1 2 Nm (1.47 lbf ft) -
Characteristics RSV4 Factory a-PRC
CHAR - 20